How Philly Swirl’s New Packaging Created a Billboard Affect in Club Stores
Philly Swirl, renowned for its vibrant and flavorful Italian ice treats enjoyed by both children and adults, has long focused on creating frozen desserts with a childlike sense of fun. Their packaging often features bold, colorful designs and tie-ins with popular children’s movies, reinforcing their playful brand identity.
When Philly Swirl launched a new product line in club stores, they turned to Great Northern to develop packaging that would meet both functional and visual demands. The graphics needed to be eye-catching and of premium quality to stand out on crowded retail shelves. Structurally, the packaging had to perform flawlessly throughout the supply chain—from printing and converting to fulfillment, distribution, and in-store display. It also needed to withstand cold, damp environments and support the product’s weight during palletization without the use of master cases, all while meeting the rigorous standards of club store distribution.
Great Northern delivered a high-performance packaging solution that not only met these technical requirements but also created a strong visual impact, serving as a billboard in the club store environment. Custom-engineered scoring profiles for the thicker substrate ensured the cartons erected cleanly and efficiently on the customer’s automated fill lines, streamlining fulfillment and maintaining structural integrity from production to purchase.
The Solution
Material
A 40 pt. laminated paperboard construction consisting of a 10pt. SBS top sheet from SAPPI and a 30pt. recycled base sheet
Special Features
Custom-engineered scoring profiles for the thicker substrate ensured the cartons erected cleanly and efficiently on the customer’s automated fill lines
Optimized Shipping
Thinner 40 pt. laminate material offers several advantages such as more cartons per pallet and per truckload

Bright, cheerful colors highlight the product and immediately draw consumer attention

The Bottom Line
Great Northern engineered a custom substrate specifically designed to maintain structural integrity in cold, damp refrigerated and frozen environments. This high-performance material meets the demanding strength requirements of club store distribution and supports the product’s weight during palletization without the need for master cases. Additionally, the use of a newly formulated recycled baseboard substrate helped reduce costs while enhancing the package’s sustainability.
Compared to traditional corrugate, the thinner 40 pt. laminate material offers significant advantages: it allows for more cartons per truckload, reduces warehouse storage requirements, and uses less overall material. Additionally, the structure’s precisely engineered scoring profiles ensure smooth and accurate forming on the customer’s automated equipment, supporting efficient and consistent fulfillment.
Bright, cheerful colors highlight the product and immediately draw consumer attention and the two beloved characters from the movie Trolls, evoke nostalgia and creates a strong emotional connection. Colorful, high-impact graphics are displayed prominently on all visible panels, creating a billboard effect that stands out in club store environments. Finally, a high-gloss UV coating enhances the overall look, adding a polished, premium finish while protecting the graphics.
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